Kawasaki 1400GTR ZG1400 2007-2013 Service Repair Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: 1400GTR Model Alias: ZG1400 Generation Production Years: 2007-2016 (ZG1400) Codes Chassis Code: ZG1400A (early models) 👋 Introduction Market Position Category: Sport Tourer / Grand Tourer Motorcycle Segment Focus: Long-distance touring, comfortable commuting, performance-oriented riding with luggage capacity. Competitive Analysis Key Competitors: BMW R1200RT, Yamaha FJR1300, Honda ST1300, Moto Guzzi Norge 1200 Key Features Engine Size: 1352cc (1.35 Liters) Engine Type: Inline-Four Cylinder, DOHC, 16 valves Transmission Type: 6-speed constant mesh Final Drive: Shaft Drive Framing: Monocoque frame construction 📋 Manual Details Coverage Areas Applicable Years: 2007, 2008, 2009, 2010, 2011, 2012, 2013 Page Count Estimated Pages: Over 800 Manual Type Type: Service Repair Workshop Manual Language Primary Language: English Format Delivery Method: PDF Download 📖 Manual Coverage Systems Covered Engine: Full overhaul, inspection, diagnosis, repair procedures for all engine components (pistons, cylinders, crankshaft, camshafts, valve train, cooling system, lubrication system, fuel injection, ignition system, starting system, charging system). Transmission: Clutch operation, gearbox disassembly and assembly, gear shifting mechanism, final drive (shaft drive), maintenance and repair. Chassis: Frame, suspension (front fork, rear shock absorber), steering system, wheel hub, bearings, spoke tension (if applicable), swingarm. Brakes: Hydraulic brake system (front and rear calipers, master cylinders, brake lines), ABS system (if equipped), brake pad replacement, rotor inspection, bleeding procedures. Electrical: Wiring diagrams, lighting system, instrumentation, battery, starter motor, alternator, ignition coil, ECU (Engine Control Unit) diagnostics, sensor troubleshooting, horn, turn signals, brake lights. Fuel System: Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, throttle bodies, emissions control system (PAIR, EVAP). Bodywork: Fairings, body panels, seat, luggage system (integrated panniers), windscreen adjustment and replacement, mounting hardware. Procedures Included Routine Maintenance: Oil changes, filter replacement, spark plug inspection/replacement, chain/shaft drive lubrication and adjustment, brake fluid replacement, coolant flush and replacement, air filter cleaning/replacement. Troubleshooting: Diagnostic charts, symptom-based troubleshooting for common mechanical and electrical issues, error code interpretation. Major Repairs: Engine rebuilding, gearbox overhauls, suspension component replacement, brake system overhaul, electrical system diagnostics and repair. Diagnostics: Procedures for checking component operation, using diagnostic tools (e.g., KDS - Kawasaki Diagnostic System, though manual covers basic checks without specific tool usage emphasis), reading error codes. Technical Depth Detail Level: Comprehensive, covering everything from basic maintenance to full engine and chassis rebuilds, including torque specifications and detailed diagrams. 📊 Manual Specifications File Format Format Details: Searchable PDF, allowing for quick keyword-based navigation and information retrieval. Optimized for digital viewing and printing. Print Quality Resolution: High resolution, ensuring clarity of text, diagrams, and illustrations. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Displacement: 1352 cc Bore X Stroke: 84.0 mm x 61.0 mm Compression Ratio: 11.2:1 Valve Train: DOHC, 4 valves per cylinder Cooling System: Liquid-cooled Engine Oil Type: SAE 10W-40 API SG or SH, or SAE 20W-40 API SG or SH (check manual for specific recommendations) Engine Oil Capacity: Approx. 4.0 L / 4.2 US qt (with filter change) Performance Horsepower Est: Approx. 155 PS @ 8,800 rpm (claimed) Torque Est: Approx. 136 Nm @ 6,200 rpm (claimed) Fuel System Fuel Delivery: Fuel Injection (DFI) with dual throttle valves Fuel Type: Unleaded gasoline (91 octane or higher) Fuel Tank Capacity: 22 Liters (5.8 US gal) 🔧 Transmission Standard Type: 6-speed, constant mesh Optional ABS: Available on some models (e.g., K-ACT - Kawasaki Advanced Coactive-braking Technology) Features Gear Ratios: Refer to manual for specific gear ratios Clutch Type: Wet, multi-disc Final Drive Fluid: API GL-4, SAE 80 hypoid gear oil (check manual for specific brand/viscosity) Final Drive Fluid Capacity: Approx. 200 ml (0.2 US qt) 📐 Dimensions Exterior Length: 2,270 mm (89.4 in) Width: 790 mm (31.1 in) Height: 1,370 mm (53.9 in) / 1,405 mm (55.3 in) (with taller windscreen) Wheelbase: 1,520 mm (59.8 in) Ground Clearance: 125 mm (4.9 in) Seat Height: 815 mm (32.1 in) Weights Dry Weight: 278 kg (612.9 lbs) Curb Weight: Approx. 300 kg (661 lbs) (depending on equipment) Front Tire Size: 120/70ZR17M/C (58W) Rear Tire Size: 190/50ZR17M/C (73W) Wheel Bolt Pattern: N/A (Cast Aluminum Wheels) 🛡️ Safety Features Ratings ABS: Optional (K-ACT on some models) Active Features Braking System: Dual 310mm petal discs with 4-piston calipers (front), Single 270mm petal disc with 2-piston caliper (rear) Traction Control: Not typically equipped on early models, check specific model variant Passive Features Lighting: Multi-reflector headlights, LED taillight Windscreen: Adjustable electric windscreen on many models 💡 Technology Features Infotainment Audio System: Some models featured integrated audio systems (check specific trim levels). Driver Assistance ABS: Available as an option (K-ACT system). Connectivity Diagnostic Port: Standard diagnostic connector for electronic troubleshooting. 🔧 Maintenance Service Intervals Oil Change: Every 6,000 miles or 6 months, whichever comes first. Oil Filter Replacement: Every 6,000 miles or 6 months, coincides with oil change. Air Filter Inspection: Every 6,000 miles, clean or replace as needed. Spark...
Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, throttle bodies, emissions control system (PAIR, EVAP).
Bodywork:
Fairings, body panels, seat, luggage system (integrated panniers), windscreen adjustment and replacement, mounting hardware.
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, spark plug inspection/replacement, chain/shaft drive lubrication and adjustment, brake fluid replacement, coolant flush and replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting for common mechanical and electrical issues, error code interpretation.
Major Repairs:
Engine rebuilding, gearbox overhauls, suspension component replacement, brake system overhaul, electrical system diagnostics and repair.
Diagnostics:
Procedures for checking component operation, using diagnostic tools (e.g., KDS - Kawasaki Diagnostic System, though manual covers basic checks without specific tool usage emphasis), reading error codes.
Technical Depth
Detail Level:
Comprehensive, covering everything from basic maintenance to full engine and chassis rebuilds, including torque specifications and detailed diagrams.
📊 Manual Specifications
File Format
Format Details:
Searchable PDF, allowing for quick keyword-based navigation and information retrieval. Optimized for digital viewing and printing.
Print Quality
Resolution:
High resolution, ensuring clarity of text, diagrams, and illustrations.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Displacement:
1352 cc
Bore X Stroke:
84.0 mm x 61.0 mm
Compression Ratio:
11.2:1
Valve Train:
DOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Engine Oil Type:
SAE 10W-40 API SG or SH, or SAE 20W-40 API SG or SH (check manual for specific recommendations)
Engine Oil Capacity:
Approx. 4.0 L / 4.2 US qt (with filter change)
Performance
Horsepower Est:
Approx. 155 PS @ 8,800 rpm (claimed)
Torque Est:
Approx. 136 Nm @ 6,200 rpm (claimed)
Fuel System
Fuel Delivery:
Fuel Injection (DFI) with dual throttle valves
Fuel Type:
Unleaded gasoline (91 octane or higher)
Fuel Tank Capacity:
22 Liters (5.8 US gal)
🔧 Transmission
Standard
Type:
6-speed, constant mesh
Optional
ABS:
Available on some models (e.g., K-ACT - Kawasaki Advanced Coactive-braking Technology)
Features
Gear Ratios:
Refer to manual for specific gear ratios
Clutch Type:
Wet, multi-disc
Final Drive Fluid:
API GL-4, SAE 80 hypoid gear oil (check manual for specific brand/viscosity)
Final Drive Fluid Capacity:
Approx. 200 ml (0.2 US qt)
📐 Dimensions
Exterior
Length:
2,270 mm (89.4 in)
Width:
790 mm (31.1 in)
Height:
1,370 mm (53.9 in) / 1,405 mm (55.3 in) (with taller windscreen)
Wheelbase:
1,520 mm (59.8 in)
Ground Clearance:
125 mm (4.9 in)
Seat Height:
815 mm (32.1 in)
Weights
Dry Weight:
278 kg (612.9 lbs)
Curb Weight:
Approx. 300 kg (661 lbs) (depending on equipment)
Front Tire Size:
120/70ZR17M/C (58W)
Rear Tire Size:
190/50ZR17M/C (73W)
Wheel Bolt Pattern:
N/A (Cast Aluminum Wheels)
🛡️ Safety Features
Ratings
ABS:
Optional (K-ACT on some models)
Active Features
Braking System:
Dual 310mm petal discs with 4-piston calipers (front), Single 270mm petal disc with 2-piston caliper (rear)
Traction Control:
Not typically equipped on early models, check specific model variant
Passive Features
Lighting:
Multi-reflector headlights, LED taillight
Windscreen:
Adjustable electric windscreen on many models
💡 Technology Features
Infotainment
Audio System:
Some models featured integrated audio systems (check specific trim levels).
Driver Assistance
ABS:
Available as an option (K-ACT system).
Connectivity
Diagnostic Port:
Standard diagnostic connector for electronic troubleshooting.
🔧 Maintenance
Service Intervals
Oil Change:
Every 6,000 miles or 6 months, whichever comes first.
Oil Filter Replacement:
Every 6,000 miles or 6 months, coincides with oil change.
Air Filter Inspection:
Every 6,000 miles, clean or replace as needed.
Spark Plug Inspection:
Every 12,000 miles, replace as needed.
Brake Fluid Replacement:
Every 24,000 miles or 2 years.
Coolant Replacement:
Every 24,000 miles or 2 years.
Fluid Specifications
Coolant Type:
Kawasaki All Season Performance Coolant or equivalent silicate-free, ethylene glycol based antifreeze.
Coolant Capacity:
Approx. 2.6 Liters (2.7 US qt)
Known Issues
Common Wear Items:
Clutch plates (heavy use), front fork seals, brake pads, tires. Fuel pump relays can be a point of failure on some units. Check for wiring harness chafing near the steering head.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycles:
Kawasaki Heavy Industries has a long history of innovation in motorcycle design and engineering, particularly in performance-oriented and touring segments.
Model Evolution
Zg1400 Lineage:
The ZG1400 (1400GTR) evolved from Kawasaki's potent ZZR-1400 (Ninja ZX-14) platform, adapting its powerful engine and chassis for comfortable, long-distance touring.
Production
Manufacturing Origin:
Japan
🏆 Awards & Recognition
Recognitions
Market Reception:
Generally well-received for its blend of power, comfort, and touring capability. Often praised for its refined engine and stable chassis.